instalación, operación y lubricación

8/17/2019 Instalación, Operación y Lubricación

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4043 120th

Street

Urbandale, lA 50323

USA Phone:

+1

-51

5-254-1260

USA

Toll free:

+1-800-383-4524

Limited

Warranty

lnsta-Pro@

lnternational warrants

to the

purchaser

of all new equipment

that

it

will

be free

from defects

in either.material

orworkmanship for

a

period

not to

exceed

either'18 months

from date of

shipment

from factory or 12 months

from date of

startup,

which ever

occurs first

and regardless

of

the accumulated

operating

hours.

The lnsta-Pro warranty

is non-transferable

and

is valid

only if

the

equipment

has

been

inspected and

initial

start-up

pedormed

by an

authorized

lnsta-Pro

technician.

Should a

failure occur, upon

notification,

lnsta-Pro v¡ill,

at

its

discretion,

repair,

replace,

or

adjust

the

defective

item or any

defective

part

of

the

item.

lnsta-Pro reserves

the

right

to

examine

the defective material or item

to confirm warranty

failure.

This

iS

accomplished by

returning

the

part

or

parts

to

lnsta-

Pro lnternational,

4043'12oth

Street,

Urbandale,

lowa

50323.

The owner

is

responsible

for

all

expenses

related

to

removal,¡reinstallation,

and

freight

involved in

the

process.

The lnsta-Pro

warranty is limited to repair

or

replacement

of

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but not limited

to

personal

injury

or

labor

costs.

The

lnsta-Pro warranty does not coven

lost

revenue

due to

loss

of

production

time.

The

lnsta-Pro warranty

does not

apply

if

it is

determined that machines have been altered,

abused or not used in accordance

with

the

instructions

as

listed

in

the

Operator's Manual.

The

lnsta-Pro

warranty does not

apply to

normal wear

and

tear of

internal

barrel

parts.

The

use

of any

unauthorized

repair or

replacement

parts

other

than original

lnsta-Pro

parts

will

void

the warranty.

No other warranty,

either expressed

or

implied,

shall apply to lnsta-Pro equipment.

lnsta-Pro

retains

the

right

to change

warranty policy

at

any

time,

without notification.

Effectlve:

September

1

6, 2009


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3/14

lnstallatlon,

0peration,

and

Lubrication

SE

ENCORE

lnstructlons

WORM

SEAR SPEED

REOUCERS


4/14

I.

SELECTIOH

The

selection

of

the

appropriate

speed reducer

for

a

given

application

requires

that

all

factors

affecting

the

operation

of

the

reducer

be

given

careful

consideration.

Service

factors

must

be applied

to

catalog

ratings

depending

on the

type

of

prime

mover

used,

the

severity of

the

application, and duration

of

daily

service.

Many

application

and

SE Encore

worm

gear

speed

reducer

selection

criteria

are discussed

in the

SE

Encore

catalog

that

is

available

at www.WlNSMlTH.com.

For

personal

assistance,

please

speak

with

a local

Winsmith

sales

representative

whose

contact information

is

also

available

on the website.

II.

INSTALLATION

1.

Shaft

Alignment

and Loading

A.

Guard

against

unusual

stresses

and

overloads

by

accurately

aligning

the various

drive

members

(motor,

speed

reducer,

coupling,

sprocket.

sheave.

gear,

etc.).

B.

Flexible

couplings

are

recomrnended

if

a

prime

mover

shaft

is to

be directly

connected

to the

inpui

shaft

or if the

output

shaft is

direcfly

connected

to

the

driven

shaft.

Note:

Flexible

couplings

hav,e

a

limited

capacity

for

misalignment.

Ensure

that

shaft

alignments

are within

the

limits

recommended

by

the

coupling manufacturer

at installation.

Even

slight

misalignments

in

a rigid

mounting

system

may

bring

about

binding,

large

vibration

forces,

or

excessive

overhung

loading;

each in

itself

promoting

premature

bearing,

shaft,

or

speed

reducer

failure.

Do

not

excessively

force

couplings

or

other

connection

devices

onto

either

input

or

output

shafts;

the result

may

be

permanent

bearing

damage.

Ensure

all

shaft

keys

are

captive

and

secured

before

operation.

C. A common

base plate

supporling the motor

and

reducer

will

help

preserve

the

original

alrgnment

between

the

reducer

and

the

motor

shaft. lf

a

structural

steel

base

is

used,

the

plate

should

be

at

least

equal

in thickness

to

the

diameter

of the

base

plated

fastening

bolts.

ln

addition,

the

structure

suppofting

the

base

plate

must

be

sufficienily

rigid

that

it

prevents

excessive

flexing

during

normal

operation.

D.

Vibration

tends

to loosen

fasteners

even

if they,

are

initially

tight.

After

the

first

week

or two

of

operation,

all fasteners

within

the

drive

assembly

should

be retightened.

Doweling

the

motor

and

speed

reducer

to

the

base

plate

will

help

maintain

alignment.

E.

Excessive

thrust or

overhung loads on

the

input

or

output

shafts

of

a

gear

reducer

may

cause

premature

failures

of

the

bearings

and/or

shafts.

Mount

gears.

pu

ie),s

and

sprockets

as close

to the

housing

as

possible'¡c

-

-

-tz:

such

loads.

Do not

exceed

catalog loads.

2.

Mounting

Positions

A.

Single

Reduction

Speed Reducers

and

Helical

Gear

Ratio

Multipliers

All

SE Encore

single reduction

spsec

.i:,:=-> :rd

all helical

gear

ratio

mu tioiliers

a.e

i

3: ,',:-

lubricant

at \^r'insR:¡

a-c

car

b:

T:-^:3:

-

a^,.,

of the

ccstt

¡ng

;¡3r¡'3c

-

F

g-.e

3

3-:as:

ír

-^c

,.^i.F-

'

^

-

=

-

.^

:

^.-

.

yr v: r

v"

i- =

_

=:

_>=_ _-

,_

_=.=

Cg-arrags

,,¡,'Fe.

:Fa

-3::'

s3-:

S

c3

0,,,

'i

a:

=Pl/1

P

ease

reference

Se::

qr

3':-

s

3::----:..

"Lubrication

&

Main:erá.cs,-

=c.

:::a

s "a

a:=c

io

proper

lubrication

level's.

B, Double

Reduction

Speed

Reducers

Worm/Worm

and Helical/Wdrm

Double

Reduction

The

SE

Encore

double

reduction

speed

reducens

are

designed

to

be

mounted

in

any

of the

"Standard"

positions

shown

in

Figure

4. These

units

are factory

filled

with

lubricant

to

a level

that

is

appropriate

for

these

standard

mounting

positions.

Standard

models

have

an

oil level

that

is

common

to

both

housings.

Grease

fittings

(not

shown

in

Figure

4)

are used

to

lubricate

bearings

when

the

motor

speed is

below

1 160

RpM,

lf

ar

additional

mounting

position

not

shown

in

Ftgure

:

is

required,

please

speak with

a local

Winsmirh

sales

representative

whose

contact

information

is

available

on the

website,

www.WlNSMlTH.com.

v

/

\y


5/14

v

v

v

3.

Mounting

Gonsiderations

The ¡'ecc.nrnended

mounting

for

a

hollow

shaft

redu:er

i'cc:porates a

iorqLre arm.

The recommended

mou'l:il-rg

of

a reducer

with

a

flange,4cracket mounting

cn a conveyor

head

shaft

uses

a

pillow

block

or

flange

bp-anng

on

the

opposite side of

the

conveyor from the

speed

reducer as

a

support

bearing.

This

provides

tnree bearings

for alignment

purposes.

lt

is

difficult

to

maintain and

align

a

system

with

a

rigidly

mounted

bearing

close

to

a

rigidly mounted

speed

reducer.

lt

is

extremely

important

to

"custom

align"

and

"custom

shim" all

components

prior

to tightening

mounting

bolts

when using a

rigid

mounting

approach.

This minimizes

misalignment

that is caused

by excessive

loads.

Select

an appropriate

key

when using

a bushing

in

the

output

bore of any

hollow

output

shaft speed

reducer.

4. G

Face Motor

Mounting

Procedures

A. C Face/Quill

Motor

Mounting

1.

Check

the

motor and

reducer mounting

registers

for

nicks that could

interfere

with

assembly;

remove

if necessary.

2. Remove

protective plastic

from

the reducer input

shaft.

The bore

has been coated

with an anti-seize

compound.

3.

Align

the

motor shaft and

key

with

keyway in

bore

and slide

motor up

input adaptor.

4. Position

the motor conduit box as

desired.

5. Secure

the motor

to the reducer using the

supplied

fasteners.

Ensure

proper

motor

seating

before

tightening

the fasteners. lf

the

motor

does

not readily seat

itself. check for axial movement

of

the moior

shaft

key

as ihis

can

cause

interference. Staking

the

keyrvay

adjacent

io

ihe

motor key will help

preveni

axial movement of the

key

during

the

mounting procedure. Draw down

evenly on the

fasteners

to avoid

bending the

motor

shaft

and tighten to 200 lbf-in maximum.

B.

G

Face Coupling

Motor

Mounting

1.

Check

the

motor and reducer mounting

registers

for

nicks

thai could

intedere with

assembly.

Remove if necessary.

2.

When

assembling

the motor and coupling,

the

coupling

halves

should

be evenly spaced

on each shaft

to

obtain

proper

engagement.

The

following describes a method for doing

this:

3.

Determine the

assembled shaft

clearance

by

measuring the distance from the C Face

to the

reducer shaft end

and subtracting

the motor

shaft

length. Mount and secure

the

motor shaft

side of

the coupling

such

that the

spider-end

of

the coupling

is located

one half of

the

clearance

distance beyond

the

motor shaft.

Mount

the

reducer coupling

half and

coupling spider

onto

the reducer

shaft

in its approximate

position,

but do

not

secure.

4. Locate

the

motor

conduit box

in

the desired

position

and secure

the motor to

the

reducer

input

adaptor

using

the fasteners

provided.

Tighten

to

200 lbf-in.

5.

Using

ihe

access

hole

in the

input

adaptot

slide the coupling

together and

tighten the

set

screw.

5. Speed

Reducer Assembly/Disassembly

lnstructions

Contact

Winsmith

or

a lgcal sales

representative

for detai

led

assembly/d

j,bassembly

i

nstructions.

6.

Sealed

vs. Vented Speed

Reducer

Operation

All SE Encore series speed

redrc"rs

are designed

to

operate sealed or

vented. Deciding whether a speed

reducer should operate

sealed or vented requires an

understanding of

the application, the environment, the

operation

of

radial

shaft seals,

and a review of the

fundamentals

of

thermodynamics that

govern

the

temperature

and

pressure

relationship in the speed

reducer.

Any significant increase in

pressure

in a sealed speed

reducer decreases

the

operational service life of the

radial

lip

seals. A

pressure

change

of

only

5

psi

may

reduce

the

seal

life

by as

much

as one third.

There

are

two impoftant

phenomena

that cause

an

increase in

the

internal

pressure

of

a sealed speed reducer.

First,

the

change of

internal

pressure

during operation

is

proporlional

to the change of

internal temperature

that

occurs during normal operation.

The relationship

follows

the combined

gas

law expressed

as

P1V1 lT1=P2Y2/12


6/14

Secondly,

radial

lip seals

can

ingest

or

"pump"

air

into

a speed

reducer

regardless

of

whether

it

is

operating

sealed

or

vented.

While

the

rate

of

ingestion

is

highly

variable

and

dependant

on

running

time

and

speed'

under

continuous

operating

conditions

the

net

effect

of

"pumped"

air

to

the

total

pressure

increase

is

significant.

the

only

absolute

method

of

eliminating

the

pressure

;ncrease

in

a

speed

reducer

caused

by

both

pumping

and

thermal

expansion.

ln some

applications,

the

duty

cycle

of

the

speed

reducer

is

intermittent,

the

run

times

shod'

and

the

temperature

increase

modest'

While

sealing

the

reducer

during

operation

subsequently

increases

the

pressure

in

these

applications,

the

increase

may

be

very

small

and

therefore

have

minimal

impact

on

the

seal

service

life'

Additionally, operating

a

sealed speed reducer may

be

the

best

choice

in

applications

where

external

airborne

FIGURE

1. Change

in

SPeed

Assumes

60%

lubricant

and

40%

air

fill

Assumes

reducer

starting

pressure

of

14'7psi

at each

starting

temperature

uses coefficient of thermal expansion

for

Mobil

Glygoyle

460

lubricant

contamination

causes

a

greater

reduction

in overall

speed

reducer

service

life

than

ihe

negative

impact

of

the

internal

pressure

increase.

The

machtne

builder

\1-

or

the

end

equipment

user

should

determine

whether

sealing

or

venting

the

speed

reducer

is

the

best

choice

for

a specific

application

as

this

decisron

has

a direct

impact

on

the

seal

service

life.

A more detailed

drscussion

of

the

factors

influencing

sea

t'¿ear

and

seal

service

life

fo lot.''s'

lnternal

Temperature

and

Pressure

lncrease

in a

Sealed

SPeed

Reducer

A

speed

reducer

experiences

a

signifrcan:

ir'iernal

temperature

increase

due

to

operating

loads'

The

'_

change

in

temperature

of

an

operating

speed

reducer

(from

static

ambient

temperature

to

maximum

operaiing

temperature) often exceeds

130'Fahrenheit'

ln a

sealed

speed

reducer,

the

increasing

temperature

*

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Reducer

Operating

Temperature

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7/14

Contaminants

Seal Lip

Lubricant

/

FIGURE

2.

lngestion

of

Air

and

Contaminant

by a Radial

Seal

Courtesy

of Parker Ha"nnifin

Corporation

results

in

a corresponding pressure increase

as

described

by the

combined

gas

law:

P1Y1

/

T1

=

P2V2l

T2

ln

a closed

system

(e.9.

sealed

reducer),

any change

in

temperature

from

one state

of

equilibrium

to

the

next

state

of equilibrium

results

in

a corresponding

change

in

both

oil volume

and internal

pressure.

Moreover,

the

thermal

expansion

of

the

lubricant

in the

reducer

can

have

a considerable

effect

on the

pressure,

temperature,

and volume

relaiionship.

The influence of

the

Iubricant's

thermal

expansion

depends

on

the

percent

volume

occupied

by

the

lubricant

compared

to

that

of

the

air.

Typically,

the

volume

inside

the

reducer

is

about

60%

lubricant

and

40%o

air.

The

thermal

expansion

of

the

lubricant

alone

increases

the

internal

pressure

in

the

reducer

by approximately

1.5

psi

when

the

change

in

temperature

is 130

"F.

Figure

1

(see

page

4)

shov,,s

ihe

total

impact

of

the

internal

temperature

and

associated

pressure

increase

at different

ambient

starling

temperatures

in

a sealed

speed reducer.

Pressure

increases greater than

5

psi

can

result

from

the

combined

effect

of

the

lubricant,s

thermal

expansion

and

the

internal

temperature

change.

Seal

"Pumping"

Effects

on

lncreased

pressure

in

an

Operating

Speed

Reducer

Correctly

operating

radial

shaft

lip

seals

are

dynamic

and

require

the

presence

of a microscopically

thin

film

of

lubricant

directly

under

the

sealing

lip.

The

seal

lip

imposes

shear

forces

on the

film

as the

shaft

rotates

beneath

it. This

creates

a seal

"pumping

action',

that

circulates

the

lubricant

residing

closest

to

the

seal

back

inside

the

speed

reducer

and

away

from

the

external

environment.

The

pumping

action

of the

seal

prevents

the

lubricant

from

seeping

out

and is

necessary

for

proper

operation.

Unfortunately,

a

correcfly

functioning

radial shaft

seal

also causes

an

unintended

and unavoidable

side

effect.

Tests

confirm

that

microscopic

air

bubbles

and

contaminants

from

the

external

environment

are

entrained

in

the lubricant.

The

actively

pumping

seal

sweeps

them

inward

with

the

induced

lubricant

flow

and

once inside,

they

escape

into

the

speed

reducer.

With

continuous

operation,

the

air

bubbles

accumulate

inside

the

reducer

cavity.

The

seal

is

acting

as

an air

pump,

causing

air ingestion

that

increases

the

internal

pressure

of

a sealed speed

reducer.

Winsmith,s

extensive

testing

has

verified

that

the

increased

internal

pressure

of the

speed

reducer

and

the rate

of

pressurization

are

dependent

on

many

variables

including

operating

time,

linear

velocity

of

the

shaft

under

the

seal,

temperature,

seal

material,

and

seal

añd

shaft

manufacturing

tolerances.

i

ln

summary,

a

significantly

large

percentage

of

sealed

speed

reducers

develop

an

internal pressure

of 5

psi

or

more

when

operated

on a continuous

duty

cycle.

This

phenomenon can

occur

even when there is no change

in temperature

because

tfre

rab¡d

lip

seals

ingest

air into

the

reducer

(see

Figure

2

-

see

top

of

page

S).

Conversely,

testing

lndicates

that

when

a reducer

operates

in

an intermittent

manner (e.g.

5 minutes

of

run

time

every

30

minutes

of

dwell);

the

internal pressure

build-up

is very

small.

The

Effects

of

Temperature

and

pressure

on

Seal

Operating

Life

The

specific

failure

mechanisms

of

seals

vary

depending

on

the

seal material.

However,

the

normal

,,wear

out,,

failure

mode

of

an

NBR

rubber (Acrylonitrile-butadiene

or

"nitrile")

dynamíc

radial

shaft

seal is

related

to

time

and temperature

and

often

termed

,'embritilement."

Over time

under

some

relative

elevation

of temperature,

nitrile

seals

loose

elasticity,

develop

micro

cracks

that

cause

an

abraded

sealing

surface

that

can

no

longer

properly

contain

the

speed

reducer

lubricant.

The

embrittlement

rate

of

NBR

materials

begins

to

accelerate

at lip

operating

temperatures

between

180"F

and 200oF.

5

v


8/14

The impact

of

increasing

temperature

and

pressure

in a

sealed

speed

reducer

on

the service

life of an

NBR seal

has

been assessed

by

numerous

seal

manufacturers.

While

the results

of these

tests

vary depending

on

variables

such

as

the actual

seal

lip

temperature,

they

indicate

ihat

a

change

in

pressure

as

small

as

5

psi

can

reduce

the

expected

seal

service life by

one

third.

This

is because

a

positive

internal

pressure

differential

in a

speed

reducer

causes

the shaft

lip

seals

to

exerl

a

higher

radial

force

on

the

shaft.

Under

dynamic

conditions,

this

force

increases

the

lip seal

contact

area

on

the shaft,

increasing

the

friction,

and

thereby

creating

a

correspondingly

higher

temperature

between

the

shaft

and

the

lip

seal.

This

increase

is directly

proportional

to

the

amount

of

radial

force

on

the seal

and

to

the

speed

of

the shaft

at the

seal

interjace

and

causes

a decrease

in

the

seal

life.

All

SE

Encore

speed

reducers

with a

quill

input

adaptor

use

special

HNBR

(hydrogenated

nitrile

butadiene

rubber)

or

fluoroelastomer

(aka

Viton@)

materials

on

all

input

shafts

because

these

materials

are

tolerant

of

higher

lip operating

temperatures.

The

typical

failure

mode

of

HNBR

material

is blistering

at

the

seal

surface'

Performance

lssues

with Bladders

and

Expansion

Chambers

Various

speed

reducer

design

approaches

aimed

at eliminating

the

internal pressure increase

have

incorporated

internal

collapsible

diaphragms

or

bladders.

Eliminating

the

pressure

increase

requires

that

the

bladder

or

diaphragm

collapse

at very

low

pressures

and

have

a

volume

that sufficiently

accommodates

the expansion

of

the air and

the

lubricant.

ln a

reducer

with

a

two inch center

distance,

the internal volume

is between

30

in3

and 40

in3.

Assuming

the

volume

is

60%

lubricant

and

4O%o

air

and applying

the

previously

discussed

combined

gas

law over a

temperature

change

of

130'F

(70"F

starl,

200'F

final),

the

size

of

an internal diaphragm

or

bladder

required

to

prevent

a

pressure

increase

must

be

between 3.9

in3 and5.2

in3.

ln

most

typical speed

reducers,

there is

insufficient

internal

space

for

such a

large

bladder.

Moreover,

while some

internal

expansion

chambers

are

effective

in limiting

or reducing

internal

pressure

rise

due

to temperature

changes,

none

are

completely

effective

in avoiding

the

pressure

build

up

related

to seal

air

pumping

action-associated

with

continuous

duty

cycle

applications.

6

Applications

Determine

When

Sealing

a Speed

Reducer

is Preferred

to

Venting

As covered

in the

preceding

discussion,

sealing

a

reducer can

increase

the

internal

pressure

which

results

in decreased

seal

service

life.

This

is especially

prevalent

when operating

under

continuous

duty

conditions.

However,

there

are

cedain

applications

where

the speed

reducer

duty

cycle

is highly

intermittent,

and

run

times are

short

with

light average

duty

loads.

Testing

and

field

experience

indicate

that

small

internal

pressure

increases

(1

-

2

psi)

have

a

minimal

effect

on

the

seal

service

life'

Another

application

dependent

situation

where

sealed

reducer

operation

is

preferred

occurs

when

the external

air environment

is extremely

contaminated

with

material

that,

if drawn

into the

reducer

through

a

vent,

can

rapidly reduce seal, bearing, or worm gear life.

ln

these

applications,

the

increased

pressure

resulting

from

operating

a sealed

reducer

can

still

have

a significantly

negative

effect

on seal

life

and,

in

these

cases,

require

more

frequent

seal

replacement.

However,

the

reducer

life

may be

lengthened

by operating

sealed

rather

than

operating

with

an

open

vent

in these

types

of harsh

environments.

Further,

the rinachine

builder

or

equipment

operator

might

(jetermine

that

the

convenience

of operating

a,'sealed

speed

reducer

outweighs

the negative

result

of

reduced

seal

service

life.

..,

The

Winsmith

two

(2)

year

warraniy

on defects

in

parts

and

workmanship

remains

unaffected

whether

an

SE

Encore

worm

gear

speed

reducer

operates

with

or without

a vent

since

the

ventlsealed

decision

only

affects the

service

life of

the speed

reducer

wear

components.

ln conclusion,

there

are

three fundamental

factors

that

govern

the

speed

reducer

seal/vent

decision.

First,

as

the temperature increases in

a

sealed

reducer,

so

will

the

pressure.

Second,

the radial

shaft

seals

are

designed

to

"pump"

lubricant

back

into

the speed

reducer.

This

pumping

action

also

causes

an

ingestion

of

air thai

increases

the internal

pressure.

Any

increase

of

pressure

causes

decreased

dynamic

radial

seal

life.

Venting

is

the

most

cost

effective

method of

eliminating

the

pressure.

Finally,

when

extreme

environmental

conditions

cause

component

or seal

wear

in

excess

of

that caused

by an

increased

internal

pressure,

*"

v

v

\¿


9/14

sealing

a speed

reducer is

the best

likely alternative.

However,

under these

conditions,

seal

wear

is

apt

to take

place

at

higher

than

predicted

rates.

SE

Encore

Venting

Solution

is

a Standard

Feature

The

SE

Encore

worm

gear

speed reducer

series

can

satisfactorily operate sealed or vented.

Each

reducer

is

supplied

with

an optional

"open-closed

vent"

that

can

be installed

by the

equipment

builder or the

equipment

user. This

exclusive Winsmith

vent

is

made

from

black

DuPontrM

Zytelo

Nylon with

UV

protection.

The vent's

design incorporates

a labyrinth with

a

dust/splash

cap

that

minimizes contaminate

and

water incursion

from

the

external environment

created

by

general,

harsh,

and outdoor

applications. The

reducer

housing

offers"multiple locations

for vent

installation

depending

on

the

final reducer

mounting

position on

the

equipment

Turning

the

top

cap

to

the

closed

position

ensures that

no

oil drains while

the

equipment

is

in

transit

to

the

operating

location.

Turning

the top

cap counter

clockwise,

by

hand,

opens the

vent

prior

to

running

the

speed reducer

A

special

screw driver

slot molded

into the

cap

allows

easy actuation

when

access is limited.

The

vent

should

be installed

in the

highest

pipe plug

location

available

based

on

the

actual mounting

orientation

of

the

speed reducer

on the

operating

equipment.

Additionally,

a bright

yellow plastic

tag

is

provided

with the

vent

that

reads:

"IMPORTANT

-

VENT

REQU/RES

ACTIVATION

.

THIS

UNIT HAS

BEEN

SHIPPED

TO

YOU

WITH THE

VENT

IN

THE

CLOSED

POSITION

-

IT IS

IMPORTANT

TO

OPEN

THE

VENT

BY

MAKING

A

ONE

QUARTER

TURN

COUNTER

CLOCKWISE"

III.

LUBRICATION

&

MAINTENANCE

NOTE:

SE Encore

worm

gear

speed reducers

are

factory

filled

with

Mobil

Glygoyte

460

(pAG)

lubricant.

The

use

of other

lubricants

may result

in

substantially

lower

torque

capacity

and is

not recommended

by

Winsmith.

lf

other

lubricants

are used,

a thorough

flushing

procedure

is

required.

NOTE:

Helical

Gear

Ratio

Multipliers

are factory

filled with

Mobilgear

600

XP 22O

lubricant.

The

use

of other

lubricants

may result

in

substantially

lower

torque

capacity

and is

not recommended

by

Winsmith.

If

other

lubricants

are

used,

a

thorough

flushing procedure

is required.

1. Factory

Filling

and Universal

Mounting

lllii

s7l$s

IP

(AN

r{},

lllgt)q

'il':

WINSMITH

www.wthstlltrl-r_e

0M

E17

MDNS

30

ttY

Siee kdel

I l'h

Positiq¡n

0

= Stanil:rrtl

,

\-\on-\ftntlard

I

:

NOTE:

All

SE

Encore

MDNS and

MDSS

standard

models

are filled

with

lubricant

by

Winsmith.

The

lubricant

level in

these

reducers.,may

be

slighily

above

the

appropriate

level

plug

in

some

orientations.

This

small

amount

of

additional

lubrication

is

normal

and

acceptable.

All

SE

Encore

MDNS

and MDSS

non-standard

models

are

filled

with

lubricant

by Winsmith

to

a level

dictated

by the

specified

orientation.

These

fill levels

are

shown

in Figure

3.

The

11th

character

in the

part

number

on the reducer

name

plate

designates

a standard

or non-standard

reducer.

A

"0"

in

the

1'1th

position

indicates

"Standard"

and

an

"X"

in the

11th

position

indicates

"Non-Standard."

2.

Ambient

Temperature

lf

the

ambient

temperature

during

operation

is

outside

of

-18

to 130

degrees

F,

please

contact

Winsmith.


10/14

3.

lnitial

Start-Up

Prior

to

starl-up.

the lubricant

level

should

always

be

checked.

The

proper

lubricant

fill

level

is

dependent

on the

speed reducer

orientation

during

operation.

The

appropriate fill, drain, and

level

plug

locations

for

a variety

of

models

and

orientations

are shown

in Figures

3 & 4. Grease fittings,

not

shown in Figures

3

&

4,

are

used

to

lubricate

bearings when

the motor

speed is

below 1 160

rpm.

lf an

alternate mounting

position,

not

shown in Figures

3

& 4, is required,

please

contact

a

local

sales representative

or

Winsm

ith

for

assistance.

FIGURE

3

^

X ]:S

X- S

XIHS

X]BS

.:.'

.-I

f--z--,

:

tt

Vr-; i

During

the

initial

starl-up

operation,

a

break-in

period

is

necessary

before

the

reducer

reaches

maximum

operating

efficiency.

Winsmith

recommends

a

gradual

application

of

load

during

the first

several

hours

after

starl-up.

The

reducer may run hot during

this

initial break-in

period.

This

is normal.

A few

drops

of

oil may

weep

from

the

lip

seals

during

the

break-in

stage.

After

a

shofi

period

of

operation,

clean

off

any excess

oil around

the

shaft

seals

and

recheck

the

oil level;

adjust if

necessary.

4.

O¡l

Change

lnstructions

When

changing

the

oil for

any reason,

use

only Mobil

Glygoyle

460

or other

compatible

PAG

(Potyatkylene

I

+-€

l

t\

]f-

O+

-r--sr-"

'_..

:.

rt.:

,.-

,l.]#+

¡il

I

?

llé

-é

t-

i

glycol)

synthetic

lubricants. lf another oil

type

is used

(PAO,

Mineral

Oil, etc.),

the

housing(s)

must

be drained

and thoroughly

flushed

with

a light flushing

oil

prior

to

refilling.

Do

not

mix

different

lubricants

in

the

reducer.

Lubricant

incompatibility

many

result

in

premature

failure.

Note:

When

changing

oil, carefully

inspect

used

oil to

be

sure

there

are no

metal

shavings,

fragments

and other

signs

of excessive

wear.

The

oil level

should

be

checked

after

a short

period

of

operation

and

adjusted

if necessary.

Each housing

of a

lV/

:

:r

-

:

ljj

lv-r'

ir

\--=--{

':i

.;r

The

oil

levelshould

be checked,

and

adjusted

if necessary

prior

to

operation

using

the

oil

level

plug

provided

and while

the reducer

is

oriented

in its

operating

poshion.

Only

Mobil

Glygoyle

460

or

compatible

lubricant

should be

used for

reducers

containing

worm

gears. The

HelicalGear

Ratio

Multipliers

should

use

Mobilgear

600 XP220

lubricant.

i..

t+


11/14

1.

Fill, vent,

level and

drain locations

a¡e

the

same for

quill

and coupled

models.

2. Double

reduction

size

E3S

and E43 models

are

supplied

with

grease

fittings

on

the ¡nput

shaft io

ensure

bearing lubrication

fd

all mounting

posit¡ons.

3.

Contact Winsmith

when

inpui speeds

are less

than 1j60

rpm

to

ensure

proper

lubrication.

A

FlcUREg&4.HARTKEy

double

reduction

model

should

be

drained

and filled

independently

when

changing

the

oil.

Visit

our website,

www.WlNSMlTH.com,

for

a detailed

flushing

procedure.

ln

many

light

duty,

relatively

clean

ambient

conditions,

the

life

of

Mobil

Glygoyle

460 is

extended

to the

point

where

a reducer

can operate

for

the AGMA

specified

,,Normal,,

reducer

life

of

25,000

hours

without

ever

changing

the

lubricant.

Note:

The

"Normal"

reducer

life

of 25,000

hours

specified

in

AGMA

6034-892

is highly

apptication

dependent.

tn

Winsmith's

'100

years

of

experience,

we have

found

that

the

actual

service

life

of many

of our

reducers

exceeds

25.000

hours

by several

multiples.

Under

severe

conditions (rapid

temperature

changes,

moist,

dirty.

or corrosive

environments)

it may

be

necessary

to

change

the

oil

at

intervals

of

1-3

months.

Periodic

examination

of

oil

samples

taken

from

the

reducer

will

help

establish

the

appropriate

interval.

The

oil change

procedure

for

all

SE Encore

speed

reducers

is similar.

The

appropriate

oil fill,

drain,

and

level

plugs

are

identified

in

Figures

3 & 4. Please

note

that

these locations

are unique

for

each

operating

position

shown.

After

draining

the

old lubricant,

nejw

lubricant

should

ne

áOOeO

to the

appropriate

level

plug'shown.

Mounting

Position

and Lubricant

Levels

for

Single

and

Double

Reduction

Models

Optimal

lubricant

level

informatron

for

single

and

double

reduction

models

is

shown

in Figures

3

and 4. Lubricant

levels

are critical

to

the

proper

operation

of

all

speed

reducers.

lf

a speed

reducer

was

ordered

and

supplied

for

a

specific

mounting

position.

it

should

not

be changed

without

contacting

Winsmith.

Altering

the

mounting

position

from

that

which

was

specified

may

result

in

inadequate

lubrication.

Contact

Winsmith

or

a

local

sales

representative

with

questions

regarding

proper

lubricant

selection

and level.

5. Long

Term

Storage

or lnfrequent

Operation

lf

a speed

reducer

is

to

stand

idle

for

an

extended

period

of

time,

either

prior

to installation

or

during

use,

the

housing

should

be

completely

filled

with

oil. This

will

protect

the

interior

components

from

corrosion

due to

internal

condensation.

Be

sure

to

drain

the

oil

to the

proper

level

prior

to

placing

the

reducer

into

service.

Contact

Winsmith

or

a

local

sales

representative

with

questions

on long

term

storage.

FIGURE

4

V-

f'

\r,

XD\D

XDTD

XDUD

XDIlD

DOUBL=

¡=DUCT]ON

lVORrrl,tORfvl

STA\DAFD

ivlOUNTli.iG

DCUBL=

REDUCT:ON

ELICAL,'r¡,;CRilr

siAf\DAtrD

LiCUItTING

XDSX

i

XS:X

i,si.{

)lSrX

:

l.

F,i


12/14

6.

Grease

Fittings

Some

speed

reducer

models are equipped

with

grease

fittings

to

lubricate bearings

that

are

not adequately

lubricated by

the oil splash.

These

fittings

must

be lubricated

every 3-6

months

depending

on

the

operaiing conditions. Winsmith

uses

Mobilith

SHC

220

or equivalent

(NLGI

#2). Caution

should

be

used

when

greasing

because

excessive

grease

may

reduce

the

pedormance

of

the lubricant

inside

the speed

reducer.

7.

Low

lnput

Speeds

(Under

1160 RPM)

When input

speeds

are

less

than

1160 RPM,

grease

fittings

will be

required

to

lubricate

any

bearings

not

parlially

covered

by

the normal

oil

level. lf a

low speed

operating

condition

exists

and

the

reducers

are

without

the appropriate

grease

fittings,

please

contact

Winsmith

or a local Sales

Representative.

8.

Oil

Temperature

Speed

reducers

in normal operation

can

generate

temperatures

of

up

to

200 degrees

F depending

on

the

type of

the

reducer and

the

severrty

of

the application

(loading,

duration of

service,

ambient

temperatures).

Excessive

oil temperatures

may be

the result

of one

or

more of

the following factors:

A. Overloads

Overloads

may be due

to the

original

model

being

too small

for the application.

Overloads

can

also

occur

if the

speed

reducer is

properly

sized

for the

application

and higher

than

anticipated

loads

are

experienced.

Always check

the reducer

rating

when increasing driven

loads or

when increasing

the

horsepower rating of

the

motor or other

prime

mover.

B. Overfilling or

Underfilling

lf a speed reducer

is

overfilled

with oil,

the

energy

used

in

churning

the

excessive oil can

result in

overheating.

lf overfilling occurs, shut

down the

drive,

remove the oil level

plug,

and

allow oil

to drain

from

the level

hole until

it

stops.

Reinstall

the level

plug

and

restarl

the drive.

lf

the

speed

reducer

is under

filled,

the

resultant

friction

can

cause overheating

and

possible

damage.

lf this occurs,

the

reducer should

be

disassembled

and

inspected

for

excessive

wear.

10

Replace damaged

components,

reassemble

the

reducer, and fill

with lubricant

to the

appropriate

levelfill hole.

\/

C.

Inadequate Cooling

ln order

to

dissipate

internally

generated

heat,

the

speed reducer must be installed

in

such

a

way

that air can circulate

freely.

Tightly confined

areas,

(inside

cabinets,

etc.) should be avoided.

lf

this

is

not

possible.

use

a separate blower

to

provide

forced air

cooling.

9. O¡l

Seals

and

Wear ComPonents

Various

normal

wear

components

such as

seals,

bearings

and

gears

may

need more

frequent

replacement

in

severe

applications.

Gear reducer

shaft

lip seals

are all

subject

to

wear.

Experience

indicates

that

their

useful

life

is

extremely

variable,

and based

primarily

on

the operating

temperature.

Other

operating

factors

that

influence

seal

life are

high input shaft

speeds

and environmental

factors

such as air-born

abrasjve

padiculates.

lnspecting

the

gear

reducer regularly

and replacing

the

shaft

seals at the

first sign thqt

they are beyond

their

useful

life is

the

only

methodof

ensuring

no lubricant

leakage.

This might be as

frequently as

2

years

or less

in some applications;

in others

it

can

be as

long as

10

years

or

more.

Winsmith

uses

high

quality

oil

seals

and

precision

ground

shafts. However,

it is

possible

that

damage

during

shipment

or

installation

can cause oil

seal

leakage. When replacing a shaft

oil

seal,

the following

suggestions will help ensure

leak free operation

and

long seal life:

A.

When installing a new seal, cover

the

keyway

and

any other

shaft

surface discontinuities

with smooth

tape

to

protect

the

seal

lip from being damaged.

B.

Use

a sealant between

the

OD of

the

seal

and the

lD of

the

bore into which

the

seal

is being

installed.

The

seal bore should also

be

free of any

burrs,

nicks,

or scratches.

C.

Be

sure

that the

seal

is not cocked

in the seal bore.

The outer face of the seal should

be

flush with the

outer surface of

the

reducer.

DuPontr|,

Zyte\,

and

Viton@

aare

registered

trademarks

of

E. L du Pont

de

Nemours and Company.

:

?

\/


13/14

WARNINGS

AND

GAUTIONS:

\l

a

v.

v

t

Winsmith

products,

and associated

equipment

and

machinery

are intended

for

selection

and

use by trained

and skilled

persons

capable

of determining

their

suitability

for the

specific

application

or

use,

Proper

selection,

installatjon,

operation and maintenance, including implementation of adequate safety

precaui¡ons,

are

the responsibility

of the

purchaser

or user.

The following

safety

precautions,

as well

as additional

safety

precautions

that may

be required

for

the

specific

application

or use, are the responsibility

of

the

purchaser

or

user.

FAILURE

TO

OBSERVE

REQUIRED

SAFFTY

PRECAUTIONS

COULD

RESULT

IN

SERIOUS

INJURY

TO

PERSONS

OR PROPERTY

OR

OTHER

LOSS.

Lock-ouVfag-out.

lt

is

EXIREMELY

IMPORTANT

that equipment

or machinery

does not unexpectedly

stafi. To

prevent

this

possibility,

all electrical

or

other

input

power

sources must

be

turned

off,

and

properly

locked

out, Tag

oif

procedures

must

be followed before

working

on or near

the

reducer

or any

associated

equipment. Loads

on

the

input

and

output snaits

should be

disconnected

prior

to working

on any reducer,

Failure

io

obsene

these

precautions

may result

in seriorr.s

bodily

injury

andior

property

darnage.

Grounding= Be

sure the

unit and

associated equipment are propedy grounded

and

otherwise installed

in

accordance

with all

electrical

code requirements.

Protective

Guarding

/ Loose

Clothing.

etc, Always

insure

there is

proper

protective

guarding

over all rotating

or moving

parts.

Never

allow loose

clothing,

hair,

jewelry

and the like

to

be

worn in

the

vicinity

of rotating

or moving

parts

oi

machinery.

The

purchaser

or user is

responsible

for

complying

with

all applicable

safety

codes. Failure

to

do so may result

in

serious

bodily injury

and/or

damage

to

property

or other

loss.

Selection

&

lnstallation,

This

reducer

and associated

equipment

must

be

selected,

installed,

adjusted

and

maintained

by

qualified

personnel

who

are

knowledgeable

regarding

all equipment

in

the system

and the

potential

hazards

involved.

Consult

Cataloq

Ratings.

Load,

torque

and other

requirements

must not

exceed

the

published

ratings in

the

cunent

catalog

and/or

on the

speed

reducer

nameplate,

and

the reducer

selected

must

be consistent

with

all

service

factors

for

the

application.

See Winsmiih

catalogs

and

rmw,WlNSlr4lTH.com.

Brake

Torque

Loads.

Whenever

a brake

cr anl,oiher

stopping

force

is lnvolved

in an

application.

braking

torque

oaCs

,r-nposed

on the

gear

reducer

must

not

exceed

the allowable

load

ratings.

Not

a Brake,

Speed

reducers

shcu

d

ne,,,er

be ssd

to

provide

the

function

of a

fail

safebrakeoranassuredself

tockir_od:,,,ce.

Speedreducersmustneverbe

used to

replace

a brake

or a critica,

brak

r-g

acc

tcatio"

iunction,

Excess

Overhung

Loads,

Excessive

overhung

loads

on

the input

0r

outpui

shafts

of

a

gear

reducer

may

cause

prernafure

faiigue

failures

of ihe

bearings

andior

shafts.

Mount

gears, pulleys

and

soroct(eis

as close

to the

housing

ás

possible

to

minimize such

loads.

Do not exceed catalog ratings.

Excess

Thrust

Loads,

Excessive

thrusi

lcads

on the

rnput

or

output

shafts

of

a

gear

reducer

may cause

premature

íailure

oÍ

bearings.

Do

not

exceed

catalog

ratings.

Alignment,

Properly

align any input

ano

output

poler

transfer

elements

connected

to

the

speed

reducer.

Even

slight mrsalignments

in

a rigid

mounting

system

may

cause binding.

large

vibration

forces

or

excessive

overhung

loads,

leading

to

premature

bearlng,

shaft. or

speed reducer

failure.

Use

of flexible

couplings

that

allow the

reducer

and connected

transfer

elements

to

self-align

during

operation

will

compensate

for

mlnor

misalignments,

Not

a

Suoport

Structure,

A

speed reducer

must

never

be used

as an integral

component

of a machine

superstructure

or support

frame

that

would

subject

it to

additional

loads

other

than

properly

rated

loads

transmitted

through

the

shafts.

Mountinq

Position,

Your

Winsmith

gear

reducer

should

be mounted

in

one of

the

mounting

positions

shown

in the

catalog.

Different

mounting

positions

should not

be

used without

contacting

Winsmith

as this

may result

in improper

lubrication.

9veñead

Mounting.

lVounting

of a

speed reducer

in

overhead

positions

may

be hazardous.

Use of external

suppoñ

rails

or structure

is

strongly

recommended

for

any overhead

mounting,

Ufting

Evebotts,

Any lifting

supports

or eyebolts

provided

on the

gear

reducer

are

supplied

with

the

purpose

to

vertically

lift

the

gear

reducer

only, without

any

other

attachments

or motors.

lnspect

such supports

and

bolts

before each

use.

Propertv

Secure

Mounüng

Botts.

Proper

mounting

bolts

and

proper

torques

must be applied and maintained

to

insure the gear reducer

ls

securely mounted

to

the

desired

machinery.

lnspect

regularly

as machine

vibration

may

loosen

fasteners.

Thread

Locking

Com¡ound.

Proper

thread

locking

compound

should

be

appropriately

applied

to the

cleaned

threads

of all mounting

bolts

connecting

or

securing

the

speed reducer

to equipment

and any

drive,

accessories,

or brake

components

attached

to the

speed

reducer.

lf at any

time

after installation a

factory

supplied

assembly

or

construction

bolt is removed,

care

must

be iaken

to thoroughly

clean

off the

old thread.locking

compound

and

a

new

appropriate

thread locking

compound

must

be

a¡fplied. Fa¡lure

to

properly

apply

new thread

locking

compound

on all mounting qi

reducer

construction

bolts may

result

in

serious injury

or death from

falling

nt6chanical

components.

Reducer

Surface

ls Hot.

Operating

gear

reducers generate

heat,

Surface

temperatures may become hot enough

to

cause severe

burns.

proper

personal

protective

equipment

should

be

used.

..,

..

Noise.

Operating

gear

reducers

may

generate

high

noise

levels.

Use appropriate

hearing

protection

and

avoid

extended

exposure

to high

noise

levels.

Lubricants

Hot

and Under

Pressure,

The temperature

of

lubricants

inside

a

gear

reducer

may

be very

high,

The reducer

should

be

allowed t0

cool to

ambient

temperature

before

removal

of any vent,

drain, level,

or

fill

plugs,

and

before

removing

seals

or bearing

covers..Gear

reducers

without

a

pressure

vent

may

also be

under

great

internal

pressure.

-slowly

loosen

the lubricant

fill

plug

above the

lubricant

level

to vent

any internal pressure

before

further

disasiemuty.

Lubricant

Contact,

Contact

wjth lubricants

can

present

safety

concerns.

proper

personal

protective

equipment

should

be used

whenever

handling

speed

reducer

lubricants.

Consult

the

lubricant

MSDS

sheet

which

is

often

available on

the

lubrication

manufacturels

website.

FDA.

USDA.

and

NSF

Applications.

Factory

supplied

lubricants

may not

be

suitable

or safe

for

applications

involving

food,

drugs

and

slmilar

products.

This

includes

applications

subject

to FDA,

USDA, NSF

or

other regulatory

iurisdiction.

Consult

the lubricant

supplier

or Winsmith

for acceptable

lubricants.

lnsoection

and Lubrication,

Regularly

inspect

the

gear

reducer

to

ensure it is

properly

operating,

and follow

all maintenance,

operation

and lubrication

guidelines

provided.

11


14/14

DISTRIBUTED

BY:

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V

PEERLESS-WINfiIilITH,

INC.

$@Z

+1#i2

sulstDtA+y

oF

ISD

trousraee

rlvc.

172

EATON

STREET

4

SPRINGVILLE,

NEW

YORK

14141-1197

PHONE:

7'161592-9310

FAX:

716/592-9546

WEBSITES:

www'WNSMlTH.com

.

www.hbdindustries.com

'El

PWS-19792-January

1/09-60M

Printed ¡n U.S.A.

\-l

instalación, operación y lubricación

Documents